Printer method and apparatus

ABSTRACT

A printer has a light source that directs light toward a print medium path. An RGB sensor is positioned to receive light from the light source that is reflected by the print medium. An infrared light filter is situated between the RGB sensor and the paper to filter out infrared light. A programmed processor is coupled to an output of the RGB sensor in order to detect form elements in the output from the RGB light sensor, retrieve a stored electronic representation of a form, match the form elements to the stored electronic representation of the form to identify locations on the form, and control printing to the form.

FIELD OF THE INVENTION

The present invention relates to printing devices and in particular toportable printing devices such as those used for printing labels and thelike.

BACKGROUND

Pre-printed (forms, etc.) or fixed size (labels, etc.) thermal mediashould be correctly aligned within a printer in order for the printingto properly register onto the media. The most common method to insureaccurate media alignment is use of a pre-printed “black mark” on theback or the front side of the media.

Unfortunately, a front printed black mark may result in a largeinter-form/label gap or may introduce an undesired element (a blackmark) to a print canvas. The back printed mark also adds complexity to aprinter design, since it requires installation of a reflectivephotoelectric sensor on the back side of the printer door. Infraredlight transmitters are traditionally used for this purpose. However,traditional infrared reflective photoelectric sensors are sensitive todirect sunlight and often fail when used in a peel-and-present printingmechanism. This arrangement is also limited to only sensing a level oftransmitted infrared light reflection from an object and suffers fromwide variations in received signal strength due to quality andvariations in the material of the sensor and its potentially impreciseplacement during assembly. More often than not costly sensor sorting andmatching operations have to be implemented to alleviate sensitivityerror.

Therefore, a need exists for a better mechanism to detect properalignment of forms in a printer.

SUMMARY

Accordingly, in one aspect, the present invention embraces a printer forprinting on a print medium having preprinted elements that make up aform. A light source directs light toward a print medium path. Ared-green-blue (RGB) light sensor is positioned to receive light fromthe light source that is reflected by the print medium. An infraredlight filter is situated between the RGB light sensor and the paper soas to filter out infrared light entering the RGB light sensor. The RGBlight sensor has an output coupled to a programmed processor. Theprogrammed processor is programmed to detect at least one form elementin the output from the RGB light sensor. In certain example embodiments,the programmed processor is further programmed to: retrieve a storedelectronic representation of the form; match the form elements to thestored electronic representation of the form to identify locations onthe form; and control printing to the form.

In certain example embodiments, an I2C interface is situated between theRGB sensor and the processor. In certain example embodiments, the formelements comprise at least one cell designated for bounding data to beprinted. In certain example embodiments, the processor is furtherprogrammed to: advance the print medium through the printer; identifyform elements in the output from the RGB light sensor as the printmedium is being advanced through the printer; and store the identifiedform elements to memory as an electronic representation of the form. Incertain example embodiments, the processor is further programmed todetect light intensity, and the processor determines that the printer isout of media by detecting light intensity below a specified threshold Incertain example embodiments, the processor is further programmed todetect light intensity and the processor determines that the printercontains print media by detecting light intensity greater than aspecified threshold. In certain example embodiments, the processorstores a dot count representing a number of lines of the print media asa measure of location along the form where a form element is situated.

In another example embodiment, a printer for printing on a print mediumhaving preprinted elements that make up a form has a light source thatdirects light toward a print medium path. A red-green-blue (RGB) lightsensor is positioned to receive light from the light source that isreflected by the print medium. An infrared light filter is situatedbetween the RGB light sensor and the paper so as to filter out infraredlight entering the RGB light sensor. A programmed processor is provided.The RGB light sensor has an output coupled to the programmed processor.The programmed processor is programmed to: advance the print mediumthrough the printer; identify form elements in the output from the RGBlight sensor as the print medium is being advanced through the printer;and store the identified form elements to memory as an electronicrepresentation of the form; detect at least one form element in theoutput from the RGB light sensor; retrieve a stored electronicrepresentation of the form; match the form elements to the storedelectronic representation of the form to identify locations on the form,where the form elements comprise at least one cell designated forbounding data to be printed; and control printing to the form.

In certain example embodiments, an I2C interface is situated between theRGB sensor and the processor. In certain example embodiments, theprocessor is further programmed to detect light intensity, and theprocessor determines that the printer is out of media by detecting lightintensity below a specified threshold. In certain example embodiments,the processor is further programmed to detect light intensity and wherethe processor determines that the printer contains print media bydetecting light intensity greater than a specified threshold. In certainexample embodiments, the processor stores a dot count representing anumber of lines of the print media as a measure of location along theform where a form element is situated.

In yet another example embodiment, a method of printing on a printmedium having preprinted elements that make up a form, involves: at aprogrammed processor, receiving an output signal from a red-green-blue(RGB) light sensor; advancing the print medium through the printer;detecting at least one form element in the output from the RGB lightsensor as the print medium is advanced through the printer; retrieving astored electronic representation of the form; matching the form elementsto the stored electronic representation of the form to identifylocations on the form; and printing to the form.

In certain example embodiments, the method further involves filteringinfrared light out of light that is passed to the RGB light sensor. Incertain example embodiments, the output signal from the RGB sensor ispassed to the processor using an I2C interface. In certain exampleembodiments, the form elements comprise at least one cell designated forbounding data to be printed. In certain example embodiments, aninitialization involves: advancing the print medium through the printer;identifying form elements in the output from the RGB light sensor as theprint medium is being advanced through the printer; and storing theidentified form elements to memory as an electronic representation ofthe form. In certain example embodiments, the process further involvesdetecting light intensity and determining that the printer is out ofmedia by detecting light intensity below a specified threshold. Incertain example embodiments, the method further involves detecting lightintensity and determining the printer contains print media by detectinglight intensity greater than a specified threshold. In certain exampleembodiments, the method further involves storing a dot countrepresenting a number of lines of the print media as a measure oflocation along the form where a form element is situated.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example printer mechanism consistent with certainexample implementations.

FIG. 2 is an example of a flow chart an overall process used by anexample printer consistent with certain example implementations.

FIG. 3 is an example of a flow chart of a calibration process consistentwith certain example embodiments.

FIG. 4 is an example of a flow chart depicting a printing processconsistent with certain example embodiments.

FIG. 5 is an example of a calibration process for ascertaining anappropriate RGB sensor output value representing an out of mediacondition.

DETAILED DESCRIPTION

The present invention embraces a printer mechanism and method ofcalibration and operation thereof.

In accord with the present teachings, a red-green-blue (RGB) color lightsensor can be used to detect pre-printed elements on the front side ofthe thermal media and to perform required media alignment for variousforms and labels (e.g., bar code labels and parking violationcitations). This eliminates any need for a black mark or/and back sidereflective photo sensor. The RGB color light sensor can be used inconjunction with an infrared (IR) blocking filter to avoid sensingerrors caused by direct sunlight and other infrared sources.

In accord with certain example embodiments, instead of using an infraredreflective sensor in the print head mechanism, an RGB color lightsensors is utilized. For example: Intersil part number ISL29120 can beused. In another example, a peel-and-present mechanism can utilize anRGB color light sensor with IR blocking filter such as for exampleIntersil part number ISL29125.

As previously noted, some label printers may utilize have a “reflective”sensor that relies on black lines or marks printed on the back of thelabel liner. The black mark tells the printer how the label isregistered. But by utilizing the RGB sensor, an image of the label canbe stored and used by the printer to achieve proper alignment withoutuse of such a black mark. Since the black mark has height, width andposition requirements that have to be considered in advance by thethermal paper manufacturer. It occupies space that could have beenotherwise used for printing user data. The RGB sensor as taught hereincan be used eliminate need for a back side mark and therefore a backside IR sensor.

Referring now to FIG. 1, a printing mechanism consistent with certainillustrative embodiments is depicted. In such an embodiment, a visiblelight source 20 (e.g., a wide spectrum visible light LED arrangement) isused to illuminate the top surface of a print medium (e.g., a rolledprint medium) 24. The visible light reflected from the print medium 24is detected by RGB sensor 28. In order to minimize noise from infraredlight, an infrared filter 32 is used to block or highly attenuate the IRspectrum from the RGB sensor 28. The output of the RGB sensor is passedvia a suitable bus (e.g., an I2C bus interface) interface 36 to aprocessor 40.

Processor 40 controls and oversees operation of the printer includingcontrol of the print queue and instructions to the printing mechanism 44to control operations such as advancing the print medium and burning orotherwise printing to the medium. Processor 40 may also controloperation of light source 20 and RGB sensor 28 utilizing instructionsstored in memory or other storage 48. Memory or other storage 48 is alsoutilized to store information representing one or more forms that may beused in the printer. The user interacts with the printer via anysuitable user interface 52.

FIG. 2 represents an example high level flow chart 100 of an exampleprocess for use by a printing mechanism such as is discussed herein in amanner consistent with certain embodiments of the present invention. Theoverall process starts at 102 after which a length of media such as apre-printed form is fed through the printer at 106. While the media isbeing fed through the printer, the RGB sensor detects at least one formelement in the output from the RGB light sensor. Such form elements, forexample, might include cells with lines around them that are intended toserve as boundaries to contain certain information. For example, in thecase of many forms including parking citations there may be a cell thatis designated as a boundary for printing of the date. Hence, thelocation of the cells and other form elements (e.g., lines or otherprinted attributes) can be used to characterize the form and to identifythe beginning of the form. So, at 110, the processor can analyze theoutput of the RGB sensor to detect cells and other form elements in theRGB sensor output so as to characterize the form and the data cells ofthe form.

As the form is passed through the printer, the output from the RGBsensor can be used to essentially construct an electronic representationof the print media at 114 and store it to memory so that the storedelectronic representation of the form can be retrieved from memory toaid in identifying the beginning of the form and assure that the databeing printed to the form is printed in the correct location. Theprocessor matches the form elements to the stored electronicrepresentation of the form to identify a beginning of the form at 118and from there can control printing to the form of the print media at122.

Turning now to FIG. 3, a calibration process for calibrating the printerto a new form is depicted in process 200 starting at 204 where a dotcount is initialized to 0. The dot count represents a count of thenumber of lines of dots as a measure of distance down the form. At 208,the print medium is fed through the printer and the dot count isincremented as the medium is fed through so as to keep track of how fardown the form the medium has been advanced. As the print medium is fedthrough, the RGB sensor reads the visible light reflected from the printmedium and passes data representing the sensor output to the processor.During this process, the processor is monitoring the data from the RGBsensor in an attempt to discover a form element such as a form's datacell(s) in the images captured by the RGB sensor. The dot count isincremented by one for every advance of the print medium through theprinter. Each form element identified and its location as measured indot count is stored.

The RGB sensor data as processed by the processor can easily detect anend of plain white or light colored media at 220 if encountered by, forexample simply measuring the light intensity that is detected. If themedia (e.g., thermal printing paper) passes over a dark coloredbackground such as a roller at the location of imaging, a low lightintensity can be interpreted as “out-of-media” (OOM) whereas a higherlight intensity is interpreted as “media present.” In this manner, ahigh to low lux transition corresponds to an “out-of-media” event aspaper is passing through the printer. Similarly, a low to high luxtransition corresponds to a “media in/media door closed” event. Incarrying out this detection of OOM, the light intensity from thedetector can be compared to a threshold (e.g., 5-15% of the maximumoutput of the sensor) to determine if an OOM event is occurring. So, ifthe light intensity drops below, for example, 10% of the RGB sensor'smaximum output, the processor can deduce that the printer is out ofpaper and generate a suitable alert.

For “peel and present” media, light intensity readings can also be used,for example, a low lux reading can be interpreted as “no label” and ahigher lux reading can be interpreted as a “label present”.

If the OOM event has not occurred at 220, then the OOM count equals zeroat 224 and the process proceeds to 228 where a dot count and sensoroutput is stored. The dot count represents a vertical location on theform. The sensor output is analyzed by the processor at 232 to determineif a pattern has been detected. A pre-printed pattern is a collection ofmatching RGB sensor readings with repeating dot line spacings(vertically and horizontally). If a repeating pattern is detected at232, that pattern represents at least a portion of the form's patternwhich can then be stored to the memory or other storage at 236 and thecalibration process is complete at 240.

An element at 216 can be detected by, for example, detecting a lightintensity corresponding to out of media, a black mark (aka, Q-mark),pre-printed text, table, drawing, cell, line, etc. When an element isdiscovered at 216, the element can be checked to see if the elementmatches a light intensity corresponding to an out-of-media value at 220.If it does, the OOM count is incremented at 252. In order to assure thatthe printer is really out of media and is not being tricked by a printmedia defect, several (e.g., 5-10) consecutive OOM detections are usedas a limit at 256.

If, at 216, an element is not discovered the process passes to 244 wherea maximum number N of consecutive blank or empty values have beenencountered. If the limit N has been reached, then the calibration isterminated at 248 with an error so as to prevent plane white paper frombeing advanced to the end of the media roll. Until the feed limit isreached, the process advances the print medium through the printer onedot line at a time at 208.

If the RGB sensor produces a signal indicative that the end of themedium has been reached at 220, the process goes to 252 as previouslydiscussed where the OOM count is incremented by one dot line. Controlthen passes to 256 to determine if the OOM count has exceeded an OOMcount limit M. If not, control passes back to 208 and the processcontinues. If the OOM count limit M is reached at 256, the OOM count isinitialized to zero at 260 and the calibration is terminated at 264 inview of the printer being apparently out of print media.

Referring now to FIG. 4, an example printing process is depicted in flowchart 300 starting at 302. At 306, the print medium (e.g., thermalprinter paper) is fed and burned for a dot line. The RGB sensor outputsa signal to the processor at 310 and at 314, the process determines ifan element has been encountered in the same manner previously described.If so, control passes to 318. If not the process proceeds to 326 todetermine if the print queue is empty.

At 318, if the sensor is not generating an OOM signal, the OOM count isset to zero at 322 and control passes to 326. If the print queue isempty at 326, the print job is deemed complete at 330 and the printprocess ends. If the print queue is not empty at 326, control passesback to 306 where the next dot line is incremented and burned.

If an out of media sensor reading is obtained at 318, then the OOM countis incremented at 334 (again, this is to assure that enough consecutiveOOM counts are received to assure that the end of the media has beenreached). If the OOM count limit is reached at 338, the OOM count isreset to zero at 342 and the printer stops printing at 346. The printermay generate an alert to advise the user that the printer is out ofmedia.

The out of media sensor reading may be calibrated by the processdepicted in the example flow chart 400 of FIG. 5 starting at 404. At 408print media, if any, is removed from the printer and the RBG sensoroutput is captured at 412. This sensor output represents an OOM signallevel for no media present. This can be stored as the OOM sensor outputat 416. Since this value can vary somewhat, the process may set athreshold near this value that is used as the threshold beyond which anOOM signal is deemed to have occurred.

Using an RGB sensor in the print mechanism can open up a wide variety ofprocessing options that can prove useful in carrying out the printingfunction. The RGB sensor can use both reflective and transmissivesensing methods for plain media detection. The RGB sensor can also beconfigured to trigger an interrupt upon detection of a particular colorand this can be used for various control functions. When a printerutilizes a back side sensor, the printer arrangement generally includesa flex cable that is routed through a paper door hinge, but this is notnecessary when the printer only utilizes a front side RGB sensor.

Thus, as described above, a printer has a light source that directslight toward a location for print medium. An RGB sensor is positioned toreceive light from the light source that is reflected by the printmedium. An infrared light filter is situated between the RGB sensor andthe paper to filter out infrared light. A programmed processor iscoupled to an output of the RGB sensor in order to detect form elementsin the output from the RGB light sensor, retrieve a stored electronicrepresentation of a form, match the form elements to the storedelectronic representation of the form to identify locations on the form,and control printing to the form.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

The invention claimed is:
 1. A printer, comprising: a light sourceconfigured to direct light toward a print medium path; a red-green-blue(RGB) light sensor configured to receive light from the light sourcereflected by a print medium in the print medium path; an infrared lightfilter situated between the RGB light sensor and the print medium path,the infrared light filter configured to filter infrared light fromentering the RGB light sensor; and a processor communicatively coupledto the RGB light sensor, the processor configured to: detect at leastone form element of a print medium based at least in part on an outputsignal from the RGB light sensor; retrieve a stored electronicrepresentation of a form based at least in part on the at least one formelement; match the at least one form element to a stored electronicrepresentation of the form; identify one or more locations of the printmedium for printing based at least in part on the match; and cause theprinter to print to the one or more locations of the print medium. 2.The printer according to claim 1, wherein the one or more locations ofthe print medium comprises a beginning of the form.
 3. The printeraccording to claim 1, further comprising an I2C interface between theRGB sensor and the processor.
 4. The printer according to claim 1, wherethe at least one form element comprises at least one cell designated forbounding data to be printed.
 5. The printer according to claim 1, wherethe processor is configured to: advance the print medium through theprinter; identify form elements in the output from the RGB light sensoras the print medium is being advanced through the printer; and store theidentified form elements to memory as an electronic representation ofthe form.
 6. The printer according to claim 1, where the processor isconfigured to determine that the printer is out of media by detectinglight intensity below a specified threshold.
 7. The printer according toclaim 1, where the processor is configured to determine that the printercontains print media by detecting light intensity greater than aspecified threshold.
 8. A method of printing to a print medium, themethod comprising: advancing a print medium through a printer, theadvancing print medium following a print medium path; receiving anoutput signal from a red-green-blue (RGB) light sensor, the outputsignal corresponding to light from a light source reflected by the printmedium, the light source configured to direct light towards the printmedium in the print medium path; detecting at least one form element ofthe print medium based at least in part on the output signal; retrievinga stored electronic representation of a form based at least in part onthe at least one form element; matching the at least one form element tothe stored electronic representation of the form; identifying one ormore locations of the print medium for printing based at least on parton the match; and printing to the one or more locations of the printmedium.
 9. The method according to claim 8, comprising filteringinfrared light out of light that is passed to the RGB light sensor. 10.The method according to claim 8, where the output signal from the RGBsensor is passed to a processor using an I2C interface.
 11. The methodaccording to claim 8, where the at least one form element comprises atleast one cell designated for bounding data to be printed.
 12. Themethod according to claim 8, comprising an initialization comprising:advancing the print medium through the printer; identifying formelements in the output from the RGB light sensor as the print medium isbeing advanced through the printer; and storing the identified formelements to memory as an electronic representation of the form.
 13. Themethod according to claim 8, comprising detecting light intensity anddetermining that the printer is out of media by detecting lightintensity below a specified threshold.
 14. The method according to claim8, comprising detecting light intensity and determining the printercontains print medium by detecting light intensity greater than aspecified threshold.
 15. The method according to claim 8, comprisingstoring a dot count representing a number of lines of the print mediumas a measure of location along the form where a form element issituated.
 16. A method of printing to a form, the method comprising:advancing a first form through a printer; receiving a first outputsignal from a red-green-blue (RGB) light sensor, the first output signalcorresponding to light from a light source reflected by the first form;identifying one or elements of the first form based at least in part onthe first output signal; storing the one or more elements to memory asan electronic representation of the first form; advancing a second formthrough the printer; receiving a second output signal from the RGB lightsensor, the second output signal corresponding to light from the lightsource reflected by the second form; detecting at least one element ofthe second form based at least in part on the second output signal;matching the at least one element of the second form to the electronicrepresentation of the first form; identifying one or more locations ofthe second form for printing based at least on part on the matching; andprinting to the one or more locations of the second form.
 17. The methodof claim 16, wherein the one or more locations of the second formcomprise a beginning of the second form.
 18. The method of claim 16,wherein the one or more elements of the first form comprise a celldesignated for bounding data to be printed, and/or wherein the one ormore locations of the second form comprise a cell designated forbounding data to be printed.
 19. The method of claim 16, wherein thefirst form and/or the second form comprises printing medium for parkingviolation citations.
 20. The method of claim 16, wherein the first formand/or the second form comprises a label.